PSP FOR REWORKING AND UPDATING THE WINCH ON CERTAIN 518 SKIDDERS - PS4663 - MAILED US AND CANADA Caterpillar

June 30, 1991
U-130
PRODUCT SUPPORT PROGRAM FOR REWORKING AND UPDATING THE WINCH ON CERTAIN 518
SKIDDERS.
5163   PS4663
NOTE: This Program has five segments to it. Two of the segments may be
administered either before or after a failure occurs and three
only after a failure has occurred. See the Action Required. The
decision whether to apply any segment of the Program is made by
the dealer. When reporting the repair, use "PS4663" as Part
Number, "7755" as Group Number, and "96" as Description Code.
The chart included in the Service Claim Allowances section
outlines the areas involved, and the criteria for claim
submission.
NOTE: This Service Letter cancels and replaces the October 2, 1990
Service Letter and its supplements of October 17, 1990 and
January 17, 1991.

October 31, 1991

Changes have been made to improve the service life of winches on certain 518
Skidders. The changes made cover many areas of the winch. However, not all
changes are necessary on every winch. Past performance of the specific winch
involved will determine which of the changes are to be made.
Areas of change are:
1. Input clutch - An improved bearing replaces the former bearing used on
the input clutch shaft. A new gear with wider teeth and two support
bearings replaces the former gear. A new shaft, spacer, hub and housing
are also added to accommodate the new gear design. To insure sufficient
retraction and clamping force of the clutch discs the manifold and
spring retainer require rework. The assembly method has also been
modified.
A change has also been made in the power train priority valve to
maintain the proper pressure to the winch control.
2. Freespool mechanism - A stronger fork, coupler, and springs with more
engagement force replace the former parts. The cover is also
reworked to accommodate the new freespool components.
3. Drum area components -
a. Double lip seals are now used at the drum.
b. The friction material in the drag brake plug is now more oil
resistant.
c. The flanges on the 255 mm diameter drum are now thicker.
d. A drum shaft with improved bending strength is now available.
e. The winch case is more rigid in the drum area.
4. Brake, brake shaft and clutch changes -
a. A higher capacity one-way clutch with a new support.
b. A new bevel gear shaft which allows the use of a longer bolt to
retain the improved viscous brake disc and reaction plate. The
reaction plate also has a dowel to prevent plate rotation and bolt
loosening.
A larger diameter bolt is now used on the opposite end of the shaft
to secure the bearing retainer.
5. Bevel gear, pinion and winch case modifications - A new bevel gear and
pinion replace the former gear set to eliminate the gear pitting and
wear which could occur under certain conditions. The new pinion has
also been redesigned to control axial movement of the pinion.
To achieve the maximum benefit from the new gear set it will be
necessary to reinforce the winch case by welding in stiffening plates.

Model Identification Number
518 94U01298 - Up* * Equipped with 518 Winches
PIN 6KC00001 - Up
95U01185 - Up*

Refer to parts list in each segment procedure when performing individual
segments.

The following repairs are authorized only as indicated:
Segment
Number Description  Type of Program
1 Input clutch and priority valve Before or after failure
2 Freespool mechanism Before or after failure
3 Drum seal, drum and drum shaft After failure only
4 Brake, brake shaft and clutch After failure only
5 Bevel gear, pinion, and winch case After failure only
(See attached segment procedures for specific rework details.)

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost) (C/L) (Sell)
comes
first
***** Segment 1 *****
0-4000 hr 100% 3 0 0 0 0
0-36 mo
4001-5000 hr
37-48 mo 33 1/3% 1.5 0 0 50% 1.5
***** Segment 2 *****
0-4000 hr 100% 2 0 0  0 0
0-36 mo
4001-5000 hr
37-48 mo 33 1/3% 1 0 0 50% 1
***** Segment 3 *****
0-4000 hr 100% 4 0 0  0 0
0-36 mo
4001-5000 hr
37-48 mo 33 1/3% 2 0 0 50% 2
-4- June 30, 1991
Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost) (C/L) (Sell)
comes
first
***** Segment 4 *****
0-4000 hr 100% 3 0 0  0 0
0-36 mo
4001-5000 hr
37-48 mo 33 1/3% 1.5 0 0 50% 1.5
***** Segment 5 *****
0-4000 hr 100% 12 0 0  0 0
0-36 mo
4001-5000 hr
37-48 mo 33 1/3% 6 0 0 50% 6
Material allowance:
The following material allowance will be made for Segments 3 and 5:
Product Age. Segment Allowance
0-4000 hrs 3 $30 US Maximum
0-36 mo 5 $170 US Maximum
4001-5000 hrs 3 $15 US Maximum
37-48 mo 5 $85 US Maximum
NOTE: This is approximately a 24-hour job to complete all segments. It
is not always necessary to remove the winch from the machine to
accomplish some of the rework items.

All parts removed (with the exception of cores used for Caterpillar
Remanufactured parts) should be rendered useless and scrapped immediately
upon completion of the repair.
Attach: (Identification And Location Of Parts)
(Segment 1 Rework Procedure)
(Segment 2 Rework Procedure)
(Segment 3 Rework Procedure)
(Segment 4 Rework Procedure)
(Segment 5 Rework Procedure)
Identification And Location Of Parts
GENERAL INFORMATION
The following parts list, along with Illustrations 1, 2, and 3, and the
assembly notes, are applicable to all of the Program segments. This list
provides for the location of the parts listed in the winch gear group.
Item No. Quantity Part No. Description
- 4 5M7914  Spacer-Valve
- 4 5M7915  Spacer-Valve
- 1 6Y9676  Spring-Valve
- 2 7G7507  Gasket-Top Cover
- 1 9G6223  Gasket-Top Cover
1 22 1A2029  Bolt
2 2 3B1250  Nut
3 2 9K2129  Spacer
4 8 5H1504  Washer
5 1 7G6316  Support
6 1 4H6520  Seal
7 1 7G6228  Shim Pack
8 1 7G6317  Shim Pack
9 1 7T9939  Cage
10 1 5H6734  Seal
11 1 2J6362  Bearing
12 1 2J6361  Race-Roller Bearing
13 8 1D4615  Bolt
14 1 6T8312  Carrier Assembly
15 1 5K8591  Bearing-Outer
16 1 3B3969  Race-Roller Bearing
17 1 1B8709  Key-Woodruff
18  (Item not shown)
19 2 7G6320  Ring
20 2 5P7606  Cup
21 2 5P7605  Cone
22 1 9X4620  Seal
23 2 7H3171  Plug
24 2 649056  Cone
25 2 4D8648  Cup
26 1 6V4427  Seal
27 1 8E1069  Plug (tan)
28 1 4S5854  Spring
29 1 9W9531  Knob
30 1 5M2894  Washer
31 1 7G6322  Retainer (Rework)
32 1 8E1047  Sleeve
33 1 5M6214  Plug-Pipe
34 4 4F7952  Seal
35 17 0L1351  Bolt
36 1 6Y1419  Drum
37 1 8E2916  Shaft Assembly
38 1 8E1046  Gear
39 1 3T9193  Spacer
40 1 7K9205  Seal
41 4 6T8487  Spring
42 1 9M7539  Seal
43 1 9W1503  Spring
44 1 4F9029  Seal
45 1 4F7391  Seal
46 1 3T7340  Housing Assembly
47 2 037501  Cone
48 2 6V2200  Cup
49 1 3D2898  Seal
50 1 8F8733  Seal
51 1 7T9940  Cage
52 3 7G6248  Shim Pack
53 1 9W1505  Cover (Rework)
54 1 8E1071  Housing
55 1 7G4969  Manifold (Rework)
56 3 9P6903  Plate
57 1 7G4973  Piston
58 3 6Y7934  Disc
59 4 9S8752  Nut
60 3 2K5965  Ring
61 1 7G4976  Plate
62 1 8E2299  Hub
63 1 8E2298  Gear
64 1 8E2302  Spacer
65 3 8H9789  Bearing
66 1 5P1713  Seal
67 1 8E2301  Shaft
68 1 9G5626  Cage
69 1 0L1732  Bolt
70 1 7G4977  Retainer
71 21 0S1594  Bolt
72 1 8F6230  Seal
73 1 1H8142  Ring
74 1 8H7521  Seal
75 1 3L1425  Bearing
76 1 8E2300  Cage
77 1 8E1441  Pinion
78 1 7M1154  Bearing
79 1 7G6267  Spacer
80 1 2D6420  Race
81 1 9G4309  Gear
82 2 7G6235  Shim Pack
83 10 0S1595  Bolt
84 4 3T9960  Disc
85 4 6P7968  Plate
86 1 7G6251  Hub
87 2 9M9545  Seal
88 1 9F1399  Seal
89 1 7G6252  Carrier
90 1 7G6255  Piston
91 1 1J2176  Seal
92 1 8F5900  Seal
93 6 3B1915  Bolt
94 2 3P5024  Spring-Disc
95 4 686642  Spring-Case
96 1 8S9092  Bolt
97 1 8E1729  Disc
98 1 2G6231  Piston (Rework)
99 2 6N7266  Shaft
100 1 9M9936  Seal
101 1 7G6232  Cage Assembly
102 1 6T8307  Wedge
103 1 8E1048  Plate Assembly
104 1 8E3480  Cam
105 20 8E3746  Roller
106 1 8E3481  Cage
107 1 8E3977  Support
108 1 8E3813  Hub
109 1 8E3488  Retainer
110 1 6B0133  Race
111 1 6B0132  Bearing
112 1 8E1440  Gear-Bevel
113 1 8E1054  Shaft
114 8 1V8784  Spring
115 1 5F3106  Seal
116 1 2H6184  Seal
117 2 1S9799  Seal
118 1 2S3029  Bearing
119 2 0L1352  Bolt
120 1 7G6713  Spring
121 1 3T1780  Spacer
122 1 9W4866  Seal Assembly
123 1 068606  Ring
124 1 6V5759  Seal
125 1 2J0157  Seal
126 1 8E2993  Fork
127 1 6F9253  Washer
128 1 6K8162  Ring
129 1 9W0035  Shaft
130 1 9W4193  Shim Pack
131 1 9W4192  Pin
132 1 7T9944  Spacer
133 1 7T9938  Shaft
134 1 6Y2689  Coupler
135 1 9W0077  Gear
136 5 6Y0755  Spring
137 2 7T9996  Retainer
138 4 0S1614  Bolt
139 1 7T9997  Shim Pack
140 1 7T9998  Shim Pack
141 1 7T9945  Gear
142 1 8E1050  Plate
143 1 7T9943  Spacer
144 1 8E1051  Cage
145 1 9W0075  Gear
146 1 067640  Seal
147 1 5M6213  Plug
148 1 1K9060  Seal
149 1 1H8171  Seal
150 1 5F1678  Seal
151 1 9W9530  Piston
152 5 6Y0756  Spring
153 1 6Y1417  Clamp
154  (Item not shown)
155 1 0S1571  Bolt
156 1 5V7190  Washer
157 1 9C4555  Spring
158 4 091133  Shim
****** IMAGE: SEBE4631.00001.001
CAPTION: Illustration 1. Part One - 518 Winch Gear Group
****** IMAGE: SEBE4631.00001.002
CAPTION: Illustration 2. Part Two - 518 Winch Gear Group
****** IMAGE: SEBE4631.00001.003
CAPTION: Illustration 3.
Notes Referring To Illustrations 1, 2, And 3
Note A: Tighten to 49 +/- 3 N.m
Note B: Tighten to 120 +/- 20 N.m
Note C: Tighten to 380 +/- 25 N.m
Note D: Tighten to 450 +/- 50 N.m
Note E: Lubricate sealing lip lightly
Note F: Lubricate bore or shaft lightly
Note G: Use as required to obtain 16.28 +/- 0.05 mm dimension between end of
pinion and shaft.
Note H: Apply 7M7260 Liquid Gasket on faces between retainer and drum
assembly.
Note J: Use as required to fill gap.
Note K: Apply 9S3263 Thread Lock.
Note L: Lubricate during assembly
Note M: Use as required to obtain 0.08 to 0.13 mm bearing end play.
Note N: Use as required to obtain 0.02 to 0.08 mm bearing end play.
Note P: Apply 7M7260 Liquid Gasket between seal and bore.
Note R: Assemble with supplier identification mark against spacer.
Note S: Apply 7M7260 Liquid Gasket on faces between gear and drum assembly.
Note T: Use as required to provide 0.22 +/- 0.04 mm backlash.
SEGMENT 1 - Input Clutch And Priority Valve
1. Remove and disassemble the input clutch using the instructions in the
518 Winch Service Manual, Form SENR3353, D & A Module.
2. Rework the 7G4969 Manifold by increasing the depth of the bore for the
piston. See Illustration 1-1. Use care when machining the manifold to
keep from damaging the existing bore where the piston seal travels. (No
tool drag marks are allowed.)
Stamp the letter "R" near the part number to show that the manifold has
been reworked.
3. Rework the 7G4977 Retainer by removing material from the spring face
of the retainer. See Illustration 1-2.
4. Reassemble the input clutch using the new part numbers listed below
and replacing other parts which are no longer serviceable.
Use the assembly instructions in the 518 Winch Service Manual, D & A
Module and the following information.
a. Install only six of the 1V8784 Springs in the reworked 7G4977
Retainer. The two spring holes in the retainer that are not used
must be 180 deg. opposite each other.
b. During assembly of the clutch, the (reworked) 7G4977 Retainer, the
7G4969 Manifold, and bearings must be pressed against one another on
the shaft. It will be necessary to check the end play of the
assembled components and shim as necessary to get the required end
play. See Illustration 1-3.
5. Priority valve rework- Machines affected by this change are:
94U1298-2081, 2083-2086, 2088-2091, 2094, 2096-2100, 2103, 2104, 2110,
2111, 2123, 2135, 2137
95U1185-2211, 2213-2261, 2263, 2265, 2266, 2268, 2269, 2272, 2275, 2278,
2281, 2283, 2284, 2287-2289, 2291, 2292, 2294, 2296-2298, 2301, 2302,
2305, 2306, 2309, 2311, 2313, 2315-2319, 2321-2325, 2327-2334, 2337,
2340, 2343, 2344, 2347, 2350-2368, 2370
Note: This rework may have been done previously. If so, the spring
will be identified by a white paint stripe and no further
action is required.
a. Remove the components (spool, spring, etc.) from the priority valve,
which is mounted between the torque converter housing and the oil
filter.
b. Replace the former parts with the new parts shown in the parts list
for the priority valve. Also see Illustration 1-4.
c. Assemble priority valve and adjust valve pressure using the
instructions in the 518 Winch Service Manual, Form SENR4083, System
Operations Test & Adjust Module.
Note: Make the following changes to the "Pressure Chart for Winch" on
Page 33 of the Service Manual.
In the column "Engine Speed", change all four speeds to "low
idle".
Add footnote: "All pressure readings to be taken with
transmission in "neutral." Reason: If the transmission is in
gear, the priority valve reading is higher than in "neutral"
because it is the same as the transmission pressure.
Segment 1 Parts List.
Reference numbers are for items in the winch illustration preceding segment
one.
Item   Former
No. Quan. New P/N Description P/N Comments
54 1 8E1071 Housing 7G4970
63 1 8E2298 Gear  9G4310
62 1 8E2299 Hub 7G4975
67 1 8E2301 Shaft 6T8320
65 3 * 8H9789 Bearing 8H9789
118 1 2S3029 Bearing 7T8486
64 1 8E2302 Spacer 9G5628
158 4 091133 Shim  none Use as required
Priority valve parts
None 1 6Y9676 Spring 7T6401 White stripe on
new spring
None 4 None Spacer 5M7914
None 4 None Spacer 5M7915
Note: * Quantity has changed from two to three.
The following items may also be required if the existing part is no longer
serviceable. The part numbers have not changed.
Item  Former
No. Quan. New P/N Description P/N Comments
115 1 - Seal  5F3106
72 1 - Seal  8F6230
116 1 - Seal  2H6184
66 1 - Seal  5P1713
56 3 - Plate 9P6903
117 2 - Seal  1S9799
122 1 - Seal As. 9W4866
58 3 - Disc  6Y7934
123 1 - Ring  068606
****** IMAGE: SEBE4631.00001.004
CAPTION: Illustration 1-1. 7G4969 Manifold
****** IMAGE: SEBE4631.00001.005
CAPTION: Illustration 1-2. 7G4977 Retainer
****** IMAGE: SEBE4631.00001.006
CAPTION: Illustration 1-3. Input Clutch Bearing Adjustment
****** IMAGE: SEBE4631.00001.007
CAPTION: Illustration 1-4. Priority Valve
SEGMENT 2 - Freespool Mechanism
1. Remove and disassemble the idler gears and freespool mechanism using the
instructions in the 518 Winch Service Manual, Form SENR3353, D & A
Module. Omit Steps 3, 13, 14, and 15.
2. Rework the 9W1505 Cover by increasing the depth of the 38 mm diameter
bore to 34.5 +/- 0.5 mm. See Illustration 2-1.
3. Assemble the freespool mechanism and gears using the new part numbers
listed below and replacing those other parts which are no longer
serviceable. Use the assembly instructions in the 518 Winch Service
Manual.
Segment 2 Parts List.
Reference numbers are for items in the winch illustration
preceding segment one.
Item  Former
No. Quan. New P/N Description P/N Comments
157 1 9C4555 Spring
126 1 8E2993 Fork  9W0005/9N4511
136 5 6Y0755 Spring 1K7041 Already in
6KC01607-up
152 5 6Y0756 Spring
134 1 6Y2689 Coupler 9W0076
The following items may also be required if the existing part
is no longer serviceable. The part numbers have not changed.
Item  Former
No. Quan. New P/N Description P/N Comments
16 1 - Race  3B3969
49 1 - Seal  3D2898
45 1 - Seal  4F7391
44 1 - Seal  4F9029
none 1 - Gasket 7G7507
10 1 - Seal  5H6734
125 1 - Seal  2J0157
128 1 - Ring  6K8162
139 1 - Shim Pack 7T9997
140 1 - Shim Pack 7T9998
124 1 - Seal  6V5759
145 1 - Gear  9W0075
****** IMAGE: SEBE4631.00001.008
CAPTION: Illustration 2-1. 9W1505 Cover
SEGMENT 3 - Drum Seals, Drum, And Drum Shaft
This segment is divided into three sections: (A) Seals and drag brake plug,
(B) Drum, and (C) Drum Shaft. ONLY those items which have failed are subject
to the terms of the Program and replaced. Items which are still serviceable
are to be reused.
Remove the drum shaft and disassemble the drum if necessary. Use the
instructions in the 518 Winch Service Manual, Form SENR3353, D & A Module.
(A) Seals And Drag Brake Plug.
1. Cut the relief areas and add the chamfer on the side of the winch case
adjacent to the bore for the large, 9X4620 Seal. The relief is to
reduce the possibility of debris collecting at this point and the
chamfer is to provide additional clearance for a new gear (if
necessary), which is wider at this point. See Illustration 3-1.
2. When cutting the relief area and the chamfer, use caution to keep the
inside area of the winch clean. Thoroughly clean the area before
proceeding with the winch assembly.
3. Rework the 7G6322 Retainer, by adding a clearance chamfer for the new
8E1047 Sleeve, before installing the new 6V4427 Seal. See Illustration
3-2.
(B) Drum
1. Replace only if the former drum is broken. The drum is directly
interchangeable with earlier drums. The flanges of the 255 mm diameter
6Y1419 Drum are thicker.
(C) Drum Shaft.
1. If the drum shaft is cracked or broken, the winch case should be
reinforced and a new drum shaft installed. If the shaft is not broken,
it is not necessary to reinforce the case.
2. See the instructions, which follow the parts listing, for information on
fabricating the necessary plates and welding instructions.
Winch Assembly
1. Install the new drag brake plug before assembling the other components.
2. Assemble the drum and shaft items using the assembly instructions in the
518 Winch Service Manual and the following information.
a. The position of the 9X4620 Seal in the winch case is determined by
which drum gear is used. The seal contact surface on the earlier,
9W0248 Gear is narrower than that on the 9X4620 Gear. However,
either gear may be used, provided the seal is properly installed.
b. If the earlier 9W0248 Gear is serviceable and reused, the 9X4620
Seal needs to be positioned closer to the center of the gear. The
seal should be installed in the case with two 7G6320 Rings between
the seal and the case. The lock ring should be omitted.
c. If the 8E1046 Gear is used, the 9X4620 Seal should be installed
directly into the winch case. One 7G6320 Ring and a 2V9404 Lock
Ring should be used also.
d. Inspect the inside of the drum for cleanliness, particularly in
corners near the reinforcing ribs. Remove any slag or core sand
which may be present on the casting surface. If this material
breaks loose in operation, it can get into the drum support
bearings.
e. When installing the tapered roller bearings into the drum gear, the
cones must contact the spacer and the cups must be flush with the
end faces of the bore in the gear. If the cups are recessed in the
gear, they may cause the drum to drag and require high forces for
rotation.
Segment 3 Parts List.
Reference numbers are for items in the winch illustration preceding segment
one.
Item  Former
No. Quan. New P/N Description P/N Comments
38 1 8E1046 Gear  9W0248
32 1 8E1047 Sleeve 7G6323
27 1 8E1069 Plug (Tan) 9W9532
37 1 8E2916 Shaft As. 7G6315 *
26 1 6V4427 Seal  5L4776
22 1 9X4620 Seal  6V6899
* The 8E2916 Shaft Assembly may require modification to add a groove which
will permit the 649056 Cone to seat against the shoulder on the shaft.
Modify the shaft as shown in Illustration 3-3 or use the former shaft as
reference.
The following items may also be required if the existing part is no longer
serviceable. The part numbers have not changed.
Item  Former
No. Quan. New P/N Description P/N Comments
149 1 - Seal 1H8171
148 1 - Seal 1K9060
25 2 - Cup  4D8648
34 4 - Seal 4F7952
6 1 - Seal 4H6520
150 1 - Seal 5F1678
21 2 - Seal 5P7605
20 2 - Cup  5P7606
36 1 - Drum 6Y1419
7 1 - Shim Pack 7G6228
8 1 - Shim Pack 7G6317
19 2 - Ring 7G6320
40 1 - Seal 7K9205
146 1 - Seal 067640
24 2 - Cone 649056
Fabrication and Welding Information
If the drum shaft is cracked or broken, the winch case should be reinforced
and a new drum shaft installed. If the shaft is not broken, it is not
necessary to reinforce the case.
General welding specifications -
NOTE: Failure to follow the following instructions WILL result in winch
case and/or bore distortion.
Use ER-70-S3 Solid Wire, 0.045" diameter.
Wire feed speed - 180 inches per minute at 18 - 19 Volts.
Gas mixture - 75% Argon, 25% Carbon dioxide.
NOTE: Unless otherwise specified, all welds are 6 mm intermittent
fillet welds, 25 mm long on 50 mm centers.
NOTE: Care must be taken to prevent damage from weld spatter on all
machined and sealing surfaces.
NOTE: It may be necessary to grind plates to provide good fit-up with
adjoining components.
1. Disassemble the drum and shaft components if they have not already been
taken apart. It is not necessary to totally disassemble the winch;
however, internal areas not disassembled must be protected from debris
generated during the grinding and welding process.
2. To provide stability of the drum area during welding, assemble the drum
shaft and related components into the winch case. See Illustration 3-4.
3. Remove paint from those areas on the case which are to be welded.
4. Fabricate Items #1 and #2 as shown in Illustrations 3-5 and 3-6.
Use structural steel with the following properties:
Minimum yield strength: 42,000 psi
Minimum tensile strength: 63,000 psi
Steel meeting the specifications of ASTM 572, grades 42 and 50 will meet
this requirement.
5. Position Items #1 as shown in Illustration 3-7 and tack weld Item #1 to
the winch case.
6. Position Items #2 as shown in Illustration 3-7 and tack weld Item #2 to
Item #1.
7. Cut the tack welds which fasten Items #1 to the winch case and remove
each set of Items #1 and #2 as a unit.
8. Weld Item #2 to Items #1 as shown in Illustration 3-7. (It is not
necessary to allow the welds to cool before completing the subassembly
welds.)
9. After this welded assembly has cooled, position Items #1 and #2 on the
winch case using the dimension in Illustration 3-7. Weld in place.
10. Remove the drum shaft and finish cleaning and painting the welded area.
Clean the inside of the winch as necessary.
11. Proceed with the assembly of the winch using the information above and
assembly instructions in the 518 Service Manual, D & A Module.
****** IMAGE: SEBE4631.00001.009
CAPTION: Illustration 3-1. Winch Case
****** IMAGE: SEBE4631.00001.010
CAPTION: Illustration 3-2. 7G6322 Retainer
****** IMAGE: SEBE4631.00001.011
CAPTION: Illustration 3-3. 8E2916 Shaft
****** IMAGE: SEBE4631.00001.012
CAPTION: Illustration 3-4. Assembly of drum shaft before welding.
****** IMAGE: SEBE4631.00001.013
CAPTION: Illustration 3-5. Item #1 Plate (2 Required)
****** IMAGE: SEBE4631.00001.014
CAPTION: Illustration 3-6. Item #2 Plate (1 Required)
****** IMAGE: SEBE4631.00001.015
CAPTION: Illustration 3-7. Position of Items #1 and #2
SEGMENT 4 - Brake, Brake Shaft, And One Way Clutch
This segment is to be performed only following a failure.
1. Remove and disassemble the clutch brake using the instructions in
the 518 Winch Service Manual, Form SENR3353, D & A Module. Omit Step
No. 4.
2. Rework the 7G6231 Piston, if necessary, to enlarge the guide holes for
the dowels to 14 mm. See Illustration 4-1.
3. Replace the former parts with the new parts shown in the list below.
A number of new parts (marked "+" on the list) must be used together
during assembly for the following reasons:
a) The new brake shaft has provision for the new, longer one way
clutch hub.
b) A 1/2-20 X 3 inch bolt is now used on the brake and clutch end of
the shaft.
c) A 5/8-11 X 2.25 inch bolt is now used on the on the gear end of the
shaft.
4. Assemble the clutch brake using instructions in the 518 Winch
Service Manual, D & A Module.
Segment 4 Parts List.
Reference numbers are for items in the winch illustration preceding
segment one.
Item  Former
No. Quan. New P/N Description P/N Comments
69 1 0L1732 + Bolt  1A1460 Brake end
103 1 8E1048 Plate A. 7G6357
142 1 8E1050 + Plate 7T9942
144 1 8E1051 + Cage  9G5412
113 1 8E1054 + Shaft 7T9941
97 1 8E1729 Disc  6Y7913
104 1 8E3480 + Cam 6T8313
106 1 8E3481 + Cage  6T8314
109 1 8E3488 + Retainer 7G6250
105 20 8E3746 + Roller 6T8486
108 1 8E3813 + Hub 7G6357
107 1 8E3977 + Support 7G6250
96 1 8S9092 + Bolt  1A1460 Gear end
The following items may also be required if the existing part is no longer
serviceable. The part numbers have not changed.
Item  Former
No. Quan. New P/N Description P/N Comments
111 1 - Race  6B0132
110 1 - Bearing 6B0133
92 1 - Seal  8F5900
50 1 - Seal  8F8733
88 1 - Seal  9F1399
52 1 - Shim Pack 7G6248
none 1 - Gasket 7G7507
none 1 - Gasket 9G6223
91 1 - Seal  1J2176
42 1 - Seal  9M7539
87 2 - Seal  9M9545
100 1 - Seal  9M9936
85 4 - Plate 6P7968
84 4 - Disc  3T9960
143 1 - Spacer 7T9943
48 2 - Cup 6V2200
130 1 - Shim Pack 9W4193
47 2 - Cone  037501
****** IMAGE: SEBE4631.00001.016
CAPTION: Illustration 4-1. 7G6231 Piston
SEGMENT 5 - Bevel Gear, Pinion, And Winch Case
This segment covers only the bevel gear and pinion area of the 518 Winch.
ONLY those items which are not serviceable are to be replaced, serviceable
items are to be reused. The pinion and bevel gear are not serviced as
matched sets, however, the new 8E1440 and 8E1441 Gears must be used together
due to the pitch of these gears being different from the former gears.
If the pinion and bevel gear are being replaced due to having chipped,
cracked or broken teeth it will be necessary to also reinforce the winch case
as outlined in the instructions which follow.
1. Remove and disassemble the pinion and the bevel gear and shaft
assemblies using the instructions in the 518 Winch Service Manual, Form
SENR3353, D & A Module. Omit steps 5, 7, and 8.
2. Reinforce the winch case as described in the section "Winch
Reinforcement" following the parts listing for this segment.
3. After the case has been reinforced and cleaned replace the former bevel
gear and pinion and with the new parts shown in the parts list below.
4. Reinstall the bevel gear and shaft assembly in the winch case using
the instructions in the 518 Winch Service Manual, D & A Module. Omit
the Service Manual reference to checking heel alignment in Step 11a
because, with the new gears, the pinion location is a fixed distance
from the bevel gear shaft.
5. Assemble the pinion using both the instructions in the 518 Service
Manual, D & A Module and the following information. Omit Step No. 11.
a) Install washer and bolt on pinion shaft. Tighten bolt to standard
torque.
b) Assure that the ball bearing on pinion shaft is seated in
counterbore of bearing cage before adjusting pinion.
c) Adjust pinion to the dimension shown in Illustration 5-1. (This
dimension is 16.28 +/- 0.05 mm (.641 +/- .002")).
d) Adjust the gear clearance (backlash) between the bevel gear and
pinion by adding or subtracting shims from the 7T6248 Shim Pack
(Item 52). Do not change the distance of the pinion axial distance
from the bevel gear shaft. The correct gear clearance backlash for
the 8E1440/8E1441 Gears is 0.22 +/- 0.04 mm (.009 +/- .002").
Segment 5 Parts List.
Reference numbers are for items in the winch illustration preceding
segment one.
Item  Former
No. Quan. New P/N Description P/N Comments
112 1 8E1440 Bevel Gear 7G6239
77 1 8E1441 Pinion 7G6234/8E2989
76 1 8E2300 Cage  7G6540
156 1 5V7190 Washer none
155 1 0S1571 Bolt  none
The following items may also be required if the existing part is no longer
serviceable. The part numbers have not changed.
Item  Former
No. Quan. New P/N Description P/N Comments
81 1 - Gear  9G4309
75 1 - Bearing 3L1425
74 1 - Seal  8H7521
82 2 - Shim Pack 7G6235
78 1 - Bearing 7M1154
80 1 - Race  2D6420
130 1 - Shim Pack 9W4193 +
143 1 - Spacer 7T9943 +
48 1 - Cup 6V2200 +
none 1 - Gasket 9G6223 +
42 1 - Seal  9M7539 +
52 1 - Shim Pack 7G6248 +
50 1 - Seal  8F8733 +
47 2 - Cone  037501 +
87 1 - Seal  9M9545 +
91 1 - Seal  1J2176 +
92 1 - Seal  8F5900 +
none 1 - Gasket 7G7507 +
Items marked with a "+" are items which are also part of Segment 4. Some of
these items will be required during the installation of a new bevel gear and
pinion if Segment 4 is not done.
Winch Reinforcement - Fabrication And Welding Information.
General welding specifications -
NOTE: Failure to follow the following instruction WILL result in winch
case and/or bore distortion.
Use ER-70-S3 Solid wire, 0.045 inch diameter.
Wire feed speed - 180 inches per minute at 18 - 19 Volts.
Gas mixture - 75% Argon, 25% Carbon Dioxide
NOTE: Unless otherwise specified all welds are 6mm intermittent fillet
welds, 25 mm long on 50 mm centers.
NOTE: Care must be taken to prevent damage from weld spatter on all
machined and sealing surfaces.
NOTE: It may be necessary to grind plates to provide good fit-up with
adjoining components.
It is not necessary to totally disassemble the winch, however internal areas
not disassembled must be protected from debris generated during the grinding
and welding process. Disassemble the brake shaft, pinion and input clutch
components if they have not already been removed.
1. Fabricate Items #1 thru 5 as shown in the accompanying
Illustrations 5-2 thru 5-6.
Use structural steel with the following properties:
Minimum yield strength: 42,000 psi
Minimum tensile strength: 63,000 psi
Steel meeting the specifications of ASTM 572,
grades 42 and 50 will meet this requirement.
2. Remove any paint from areas which are to be welded.
3. Place Item #1 in position as shown in Illustrations 5-7 and 5-8,
Section B-B. Assure that the plate makes full contact with the front of
the winch case and the back of the pinion bearing mounting bracket.
Tack weld in place to only the front of the winch case and pinion
bearing mounting bracket.
4. Place Item #2 in position shown in Illustrations 5-7 and 5-9, Section C-
C. Assure that the plate makes full contact with the front of the winch
case. Tack weld in place to only the front of the case.
5. Weld Items #1 and #2 to ONLY the front of the winch case or pinion
bearing mounting brackets, using the dimensions shown, and alternating
between each plate until the weld is completed.
6. Position the rear of Items #1 and #2 so they make full contact with
the winch case. Tack weld in place.
7. Weld Items #1 and #2 to the winch case, using dimensions shown,
alternating between each plate until weld is completed.
8. Position Item #3 as shown in Illustrations 5-10, 5-11, and 5-12,
Sections F-F and G-G. Tack weld in place.
9. Position Item #4 as shown in Illustrations 5-10, 5-13, and 5-14,
Sections H-H and J-J. Tack weld in place.
10. Position Item #5 as shown in Illustrations 5-9, 5-15, and 5-16,
Sections C-C, D-D and E-E. Tack weld in place.
11. Now weld Items #3, #4, and #5 to the winch case using dimensions
shown. Alternate from plate to plate, to keep the heat input low, until
welds are complete.
12. Clean the winch case.
13. Install any hydraulic tube assemblies removed from the winch case.
14. Assemble the remaining components using the instructions provided.
****** IMAGE: SEBE4631.00001.017
CAPTION: Illustration 5-1. Bevel Pinion Location
****** IMAGE: SEBE4631.00001.018
CAPTION: Illustration 5-2. Item #1 Plate
****** IMAGE: SEBE4631.00001.019
CAPTION: Illustration 5-3. Item #2 Plate
****** IMAGE: SEBE4631.00001.020
CAPTION: Illustration 5-4. #3 Plate
****** IMAGE: SEBE4631.00001.021
CAPTION: Illustration 5-5. Item #4 Plate
****** IMAGE: SEBE4631.00001.022
CAPTION: Illustration 5-6. Item #5 Plate
****** IMAGE: SEBE4631.00001.023
CAPTION: Illustration 5-7. Locations of Item #1 & Item #2 Plates
****** IMAGE: SEBE4631.00001.024
CAPTION: Illustration 5-8. Section B-B of Illustration 5-7
****** IMAGE: SEBE4631.00001.025
CAPTION: Illustration 5-9. Section C-C of Illustration 5-7
****** IMAGE: SEBE4631.00001.026
CAPTION: Illustration 5-10. Right Side View of Winch Case
****** IMAGE: SEBE4631.00001.027
CAPTION: Illustration 5-11. Section F-F Illustration 5-12. Section G-G
****** IMAGE: SEBE4631.00001.028
CAPTION: Illustration 5-13. Section H-H
****** IMAGE: SEBE4631.00001.029
CAPTION: Illustration 5-14. Section J-J
****** IMAGE: SEBE4631.00001.030
CAPTION: Illustration 5-15. Section D-D
****** IMAGE: SEBE4631.00001.031
CAPTION: Illustration 5-16. Section E-E